Cummins 22-Group System Exploded DiagramIntroduction . How To Use The Manual age I How To Use The Manual All references to engine components in this manual are divided into 22 specific groups. The organization 1s consistent with the service bulletins, service parts topics, and the parts catalogs for your convenience in updating the shop manual Table of Contents The Table of Contents in the front of the manual contains a quick page reference for each group number Group Contents Each group contains the following informatio’ ‘+ A group index page at the beginning of each group to quickly aid in locating the information desired ‘+ General information to aid in rebuilding the component and an explanation of design change differences. ‘+ Step-by-step rebuild instructions for disassembly cleaning, inspection, and assembly of the component. ‘* Symbols which represent the action outlined in the instructions. The definitions of the symbols, listed in four languages (English, Spanish, French, and German), appear on pages r-5 through +8. Index ‘An alphabetical index 1s in the back of the manual to aid in locating specific information, Metric Information Both metric and U.S, customary values are used in this manual. The metric value 1s listed first, followed by the U.S. customary in brackets. An example 1s 60°C [140°F].Section | Introduction ne Symbols earn Benes Page ed Generic Symbols, “The fallowing group o symbols have been used in ths manual to help communicate the intent the struction. ‘When one of the symbols appear, it conveys the meaning defined below. @ } °ORFONO@SED P WARNING Serious personal injury of extensive property damage can result if the warning instructions are not followed. ngine can be damaged CAUTION. Minor personal injury can result ora part, an assembly orth ifthe eautlon insttuctions are not followed. Indicates a REMOVAL or DISASSEMBLY stop Indicates an INSTALLATION or ASSEMBLY stop. INSPECTION 1s requred, CLEAN the part or assembly PERFORM a mechanical or ime MEASUREMENT LUBRICATE 1 part or assombly Indicates that a WRENCH or TOOL SIZE will be oven. TIGHTEN to a specific torque, PERFORM an sloctneal MEASUREMENT Refer to another locaton inthis manual or another publication for additonal information, ‘The component weighs 23 kg {50 bor more. To avod personal mjury use a host or assistance to lift the component. " on =‘Section + Introduction ene inst segten i Gaver Saatylatryctong General Safety Instructions Important Safety Notice A waRning Improper pratons or erlassnes can cause burns cu, mutation, aspytin or other bodlymury Road and understand al of tha saat precautions and waringe before tha geraal cally precautions that must e finned fo prove personal Ineiddes ine procedures whan thay ape. + Masur he work ara srouncing ho product dy. wel it, vrtted tee rom cute 1088 tol, pars, Ignition seures eng hazardous sustancos So ware ot hasardous canglone tt can Se + Aiwaya wear protecive gosoet and protective shoes whan working. 1 Rotating parte can aus eu mtlaon or sangutaon 1p nat wea lose iting of tra ething, Bemave al alr whan werkng. 1 Disconnoet ine attary (regs |] saa) an charge any capactrs Belov bagnning any repr wok, ‘Bonne! tha Sateg mot |eupeate pez cram pre sang, Pura Do ot Cporate + UL ONL Re pope: engine arnngfecyngues for manualy otaing the engine. Oo nots atte the {vantahah by pulig orpryna onthe fon, The preclca can cause se"aus persona mr. propery damage, ‘or damape tthe fan Blado(s} causing promatre fa fae + Taengine at been operating and th conan shat allo The engine 0 ¢20 before you slowly los he Ilr £35 and feleve te pnstre Fom the cooling str + Donat wart on anything hata supported ONL by Ing ache or hot. Always us {erruppon ine produ! bole pecorming Sry eres work + fica ll pressuroin nec of asthe cooing sam balere ry ine, ngs oes Rams ae removes (Sr iiconnoctnd: Ge slat for passa pressure whan @zcsmrecing ay device om 2 ajar tha zee ‘Breese De not chock tor pressure lak vath your hana. Pgh peceura ol ote can cae poronal my + Tesovatsuecaton and rosin, waar protacve clothing ana ONLY ksconnoet Kaa retigarat eo") Unga m awl venlated aya, Tapslect ihe enoronmse, gud rotigeansyetoms mast oe propery eoted {ta ed using equipment that prevent fhe release of rogeran gas ucrocrbons) ns th atmos Federal law ronures captive and rye tangarant + Ripoaporonalin neat roe secuncewheniticmponettnal woot 284g or mee {ska sural ing devoay such Be Sain, novia, singe te good eandilon ang ara ot tng any ropa. Tis ist contains Special safety precautions are plscke or proper stands + Cérrauinn mtsor estan sie not getthesubetanos your ees. Avoid pong or repated contact ‘ith ako’ a not ewallow miro. case of contac ramacisay wash stn wth foxy ane wate in ease ‘lontac rmeiately loos ey wi lsge aruris of water or minnum o 3 mas, MMEDATELY GACOAPHVSICIAN. KEE® SUT OF REACH OF CHILDREN. + Nap ae Mat Ey Ketone (EX) are fammsble manele and must be used wth caution Follow the ‘manufacturer's nsucons lo peonde compte slay whan Us Inese matarias. KEE QUT OF REACH OF oHLoREN, + To avtd burs, be ale for not pats on products that have ust been turned OFF and hot den nes, tubes, and compartmant, + Kiway use tal that ten goad contin. take aur you undectand how o use tham belor pefrming {ny sorice work Use ONLY genuine Cummins x Cumrns Recon repiacormrt Dats + Kiwaye use the sare faslaner par mumbo (or egavaien) when rpuacng aston. D> not use stoner ‘ieuer quabty #roplocement are nacssssry. + Bont prtorm any raph sigue or al consuming soho or drugs tha can mpar your luncbonng. 1 Some uate and taderal agence mtn Unites Stes Anonca have demand that yees gine a ean be carcmogene end ean cause "oprogucive tay Aud nsalaon of vapor, ingestion ane pralenged onset wih ed angie ot‘aeneralRepatrnstuctons: Section Intadyetlon Page rio Bisene General Repair Instructions “This engine ncorporas he lalest dese technol9ay atthe time twas manufactures yet its deigrad Yo be ‘paired ueng notre! fp pracicas potsrmed t0 Qual standards, + Cummins Engine Company, ine. does not recommend oF authorize any modliicaions or repairs to Sngines or components except for those dotalea mn Cummins Service Information. In particular une Scihonaed topo to safetyreiatea components can cause personal mjury ef death, Below m 8 peta isting of components ciasiied a slaty relate: ‘Ar Comprecsor ‘ir Shotot Assombsios Balance Worghte Cooling Fan Fan Hib Assembly Fan Mouating Grackat=) Fan Mounting Capserewe Flywhoe! Flyheet Crankanat adapter lywhest Mounting Sapserows Ful Shutot Assembla Fue Sippy Tubes Ltting Brace Thre Conte ce socharger compressor Casing ‘Turpocharger Of Grain Line() Turbocharger Ol Supaly Linas) Turmocharger Turoine Casing Vibration Gemper Mounting Capscrews + Follow Ail Safety instructions Noted nthe Procedures, Flow the manutacturer's recommendations for cleaning salons and other substances used dung the Fopsr ofthe angne, Same svants snausod engine a have been Gennes by govarhmentsganies at {She or earenogenie. Avid excessive bearang, sion ond contact with such svbstances. Always Use 008 salty precise win ovis ana eaupmest “+ Prowde A Clean Envwonment and Follow the Clesnms Instructions Specilad inthe Procedures ‘Tha engine and its components must be ke clean dung any reps Contamination of he engin or Components wi eaves pomatire west + Perform the inspections Specitiad in the Procedures. ‘+ Replace all Components or Assemblies Which are Damaged or Worn Seyond the Spectizations ‘Use Genuine Cummins Nev or ReCon Sarvce Pats and Resombils “The sscombly structions have bean witan lo use again && many componente and aeaembl3s at posable. When is necessary to fplace 8 composer sr assembly. the pocedaresa based on he Ue trou Curmmins oF Cummins Racons components All the ropa gemess desonbet i th Mena {re availa om all Cummins Dirbouors ana most Deel locaton Follow The Specified Disassembly and Aasembly Pracedures to Avid Damage tothe Components, Dompleterebuisinatuction are avaabia ne shop manual when canbe orderedox purchase rom aus SGihoreed Ropar Laesiion, Pele s9 Section ¢,Useraur, for ordenng mstrustoneIntroduction General Cleaning Instructions meager General Cleaning Instructions Solvent and Aeid Cleaning ‘Several aoliet and atte cana can be Used to ciagn the engie pats, Cummins Engine Comp ine oes no recomend any speci cleaners. Away lot fa Seurar arulacare natcte Excenence has shown hat the best ess canbe obiaines using & cada hal can Be hates 1 306 £2 egress Cel [100 e200 cogtos Faron). A lesing tanta proves a constant hing ad ‘Sonn! te Soanng satan wl ge the bat ea Rel erro stn gett mata. cng, andthe depos asuig, cabon ee ita wre shor caper sive puting she parsinccatung tn Be aroma carnage any gaia ssracen When pos osm Goan the pans botre pang inom the Sang te (A. Weng: Ad exeonely dangerous, and can damoge the machen. Alay prow tank of tong ‘etn ater as a neutral agen Finae aetna pare ot ear ter caning Ory completly wih sumresed ac Both mse water tom Slt tpscew nes snd ae! ge ttn pars are not abe used immediately ser clase, os hem a sulablerusiproting compound. The tustreeung comyaund must be vemred arn he pars bate talon on he engine steam cleenng en carescn monet conc angi aod (A. roe nr pocne tig rit pra i ham ah ris eee On aon en ee pen Comore 2 ves 2 neces ‘roe Pimp 5 coe ag Hoes © sew sige o¢ Pate Bead Cleaning Glass or plastic beas clearing canbe used on many engine components o remove carbon depasis, The leannabocoosm ano by ee fhe goo Ba and, he pray peeae ard e AA Sarton: Bo not use lasso plas bead elsning on shuminum piston skits, Do rot use ‘a fesuitm prmatute wear Yao, turbocharge shat, Stey an ‘rections sted he procesures. NOTE: Pst beac lasing mea, PartNo, 2822725, cn be usd clan aluminum mag groves, Denote Sy Beas basting mesa of pn reer lamin sh Fotlow the equlpment manutscturer's cleaning neruetions. The folowing gudelins can be used t adapt lo 1 Beagame: Use US. see No. 16-20 fo paston lesrng with pase bead medi, Pari No, 9822795. Ure US “ue No 70 for paton aomee mtn gaze masts Use US. ss No. 60 for geneal purpose aening wih glass medi, 2 Operating Pressure: Glass: Uso €20 KPa [90 pi] for gonaral purpose cleaning. Plastic! Use 270 KPa (40 pal or proton sleening {Steam clean or wash the pars wth solvent fo romovo all othe foregn maton and lass or plastic Dende ster csening ince wit ho water Ory wih Sompraseed or 4 Do not contaminate the wash tanks with gla o plate beads‘Gloseay of Terms Sent ac. are: roo: oc Creumterantat Disco: Concent cpt ‘cummins Sealant: be. ye Pensa Mathes clearance: ESN. Io, Leet 290 Lectin 608 Laie 105: Section Intgdtion Sen Glossary of Terms Datintton Aacnating Currant ‘Fuel Contel dence te fue pump ta its the tal liar unt ‘het i utlcent sha manos presare eae for complete combust, ‘Ange Tp Daa Centr relore tthe poston of he piston Sheeran ‘auth Pra pcton mowing coward onthe Powe ste or mass sete Boom Dad Carer afer the postion fhe piston othe cranks rd yPumal The poten atts lowest poston the Gidar be car noi puso nat SE vseeniarbs Inthe recon ox erie m epee fo te covering oe ound pa or 2 ‘A measure of he eitference between the contr of ether to a mote Tanseereen on mrp ers te a esaeuepe Brera an Sat a Pyar serene erate oad Smal sc a enn pe ‘Te clearance m en assembly cetrmined by psig he shat in an esa ‘Tracie one woy and than pushing sso the eter wa Engne Sanat Number ‘Anand tol consting of hard ste! head on 8 hana. nade Dimer ‘Asn comgonent anaes, polyester rn, qu sealant compound that {utara Senter coun ted ral surtesefroducg a odgh tard bona jet prose ia Pana Lae He 128. ‘A snglecomposenteaerbre aud aahesve ia meets of weeds her Suea ie Pinta ateae all PEt ‘ome fs eau procul re Loctite 601 and Pamabond HL 188 ‘A manera base aase with calcu soap (2 percent 8 peer, and SuTege patent # par} acaoes